D-Mac's rat bike to......cafe bike? Here we go again.

[D-Mac]

Continued….

The headlight is easily the biggest improvement from powdercoating. It looks even better than the pics show. The powder covered all the scratches perfectly. I replaced all of the rusty fasteners and rotted rubber bits too. Some pics of this beauty.






The new swingarm bearings went in with ease. After a night in the freezer I was able to tap them right in. Pleasant surprise. The powdercoater did an excellent plugging the holes and avoiding excessive build-up around them.

Steering head races (especially the top one) were a little tougher to get on. I used some heat gun to warm up the neck a bit and dropped in frozen races. I ended up using the old races and a couple of sockets to drive them in fully. [I do have access to a great tool to gently force them in, but I was impatient and wanted to see if I could drive them on before borrowing or making something to do it]

Top of head, before


Race seated.


Driving the lower bearing onto the steering stem was a pain. I had a perfect PVC pipe to drive it on, which made short work of it with a little caveman hammering. I put the stem in the freezer overnight beforehand. Yes….I remembered the little spacer/dust seal on the bottom, although I should have used the aftermarket one that came with my bearings because it fits better than what Suzuki uses. Oh well, this bike isn’t going to spend much time in the rain anyway. The original top dust seal fits well (better than the aftermarket one I had). I was sure to grease the bearings and everything else with enough high-impact grease to last a loooong time.

The service manual calls for torquing the main steering head nut to ~30 ft-lbs and then loosening it ¼-1/2 turn until it “feels right” (checking for looseless via the fork tubes when they are assembled). Since the bearings are new, I want to do it right (I know what “feel” I’m ultimately looking for after that). Of course I don’t have the 4-pronged Suzuki tool for the stem nut (the nut pictured below is the top clamp nut that goes on top of it….different nut). I think the shop where I’m taking classes has one so I’m taking the frame and stem there tomorrow to do it. If that fails, I’ll have to make one. After that I can get the forks, swingarm, and wheels on.

Here’s a pic with the top clamp just sitting on the head.


Unfortunately, I’m away most of the week so it could be several days before I get back to it. After that I will have a lot of free time to work on the bike. Stay tuned…

[Max Wedge]

Nice job Dean! That is going to be a nice ride-something to be definetly proud of. Thanks for posting the build, makes me want to start one myself, then I remember how much work it is.  

[veefer800canuck]

One of my co workers is buying a Kawasaki 750 triple 2 stroker tomorrow.

He wants to do it up as a resto mod, upgrade the swingarm, forks, wheels and brakes, brace the frame by adding some tubes and triangulating it a bit to stiffen up the chassis, but he also wants to keep the bike mostly stock looking. (body/paint wise)

Apparently the bike he's getting is like 80% mechanically done, and just needs some finishing to be rideable in stock form.

I'm going with him tomorrow to pick it up, I should take pics and start a thread.

[D-Mac]

Some exciting news! Last week I got this project looking more like a motorcycle. I began by installing the rear tire on the rim and borrowing the “special” tool needed to torque the steering head nut correctly.

Once this was done, I assembled the forks, front wheel, front caliper, inner fender and clip ons. I then pushed the forks up through the tree and re-clamped the clip-ons to the top. I checked and re-checked the rake and trail numbers and I still have lots of room to spare.

Front wheel on:


Front caliper installed:


Headlight on:


Swingarm installed:


Rear wheel installed. Shocks partially done:


Rear caliper and brake arm:


Clip ons adjusted:


Got new brake lines. Love these things!


More pics in the next post….

[D-Mac]

A few pics of the bike. Sidestand re-installed too. Since these were taken I’ve replaced a lot of fasteners, replaced the grips/levers, and I’m working on the footpegs and brake lever – removing rust, treating them, polishing them, and clearing them. I will do rearsets eventually, but I’m going back to stock for now.









I also ordered and just received a K&L engine stand. I’ve wanted one for a long time. This will make any bottom-end work a snap, including painting the rest of the engine (recall that I’ve already painted the top-end components of my “parts engine” but I need to do the bottom end of the engine I plan to use). You can tear a bike down to the crank almost effortlessly since you can easily flip the engine upside down. The bottom piece seemed a little too long, so rather than cut the one that came with the stand, I bought a piece of square tube and cut it down a bit. In retrospect, the original piece might have “just” fit.

Anyway, some pics of the “original” 550 engine in the stand.






I ordered the Caswell gas tank liner so I can properly coat the tank. There is some old stuff in there (looks like Kreem?) that I will be removing first. A gallon of paint stripper, a jug of acetone, and some drywall screws oughta do it. After re-lining and stripping the paint off the tank I will assess the leak(s) (I know there is one already). If they are small, the Caswell liner should take care of them. If they are really bad I’ll learn how to solder the tank. Once the liner is done I’ll move on to patching the dent and painting it.

There is still tons to do…..engine work and a dreaded electrical odyssey. I’m currently taking a course that includes honing motorcycle cylinders, and cutting valves and valve seats. I plan to do mine in about a month or so. I finally ordered new rings and piston pin clips, so I now have all of the stuff to re-build the top end.

[D-Mac]

One of my co workers is buying a Kawasaki 750 triple 2 stroker tomorrow.

He wants to do it up as a resto mod, upgrade the swingarm, forks, wheels and brakes, brace the frame by adding some tubes and triangulating it a bit to stiffen up the chassis, but he also wants to keep the bike mostly stock looking. (body/paint wise)

Apparently the bike he's getting is like 80% mechanically done, and just needs some finishing to be rideable in stock form.

I'm going with him tomorrow to pick it up, I should take pics and start a thread.

Pics?? He'll want to strengthen the frame. Those things were verrrrry "flexible."

[veefer800canuck]

Looks great D-Mac. I'd probably find something to cover those braided lines with where the metal clamp holds them to the swingarm.

Maybe some clear vinyl tubing, the length of the metal clamp, I.D. just right for the brake line, and slit along it's length, slid between the clamp and hose?

[veefer800canuck]

Pics?? He'll want to strengthen the frame. Those things were verrrrry "flexible."

Well I didn't take enough pics to justify a thread, so here's the quick and dirty version:

He traded this:





For this:



Plus a boxful of spare parts. Engine is fully rebuilt as are the carbs. Top end, bottom end, clutch, tranny, etc, etc.  

He wants to Cafe' it, and I'm trying to steer him towards doing this:



Modern forks, swingarm, brakes, wheels, radial tires, shocks, etc.

\threadjack

[D-Mac]

Looks great D-Mac. I'd probably find something to cover those braided lines with where the metal clamp holds them to the swingarm.

Maybe some clear vinyl tubing, the length of the metal clamp, I.D. just right for the brake line, and slit along it's length, slid between the clamp and hose?

They come with a clear vinyl finish on top of the metal, so they won't scratch anything, but you're right that I'll want something on top where the clamps are located to help hold them in place a bit better.

[sleazy rider]

That pup is looking sweet, Dean.  Very nice work.  I can't wait for the inaugural RTE.

[sleazy rider]

Dean, you still alive?  

[D-Mac]

Dean, you still alive?  

LOL. I got swamped with classes for a while. Then we bought a house, so I spent a few weeks preparing ours for sale. As part of that process, I had to put the chassis into storage until ~August 10th, when we move.    I did get the tank and cowling ready to paint, but I have no funds to do it right now, so that's on hold too (I have some pics of the tank prep I think, so I'll post them up). The engine is nearly ready to reassemble, and I'll be honing the cylinders, replacing the rings, and cleaning up the valves and seats within the next few weeks and posting that up.

On the upside, my new garage will have ~1200 square feet devoted ENTIRELY to motorcycles.  

[D-Mac]

September 15, 2012

Part 1 of 3

OK….so where were we…..

First thing I did since my last update was strip the old paint off the tank. No more “redneck rocket!” About time really.

Bike before:


Here is the tank after stripping:


I then rinsed the inside of the tank with acetone. It lifted off the old Kreem layer immediately. I then applied Caswell liner from their motorcycle tank kit, which has received rave reviews from restorers. I had a very tiny leak near the back and it plugged it right up too. This stuff looks and feels like honey when it goes on and it leaves a nice even, clear layer over everything. I’m confident the tank is near bullet-proof now. Because I just left the tank exterior untreated, it quick built up some surface rust, but it should come right off when it gets painted.
This summer I also took two motorcycle-related classes to improve my skills. One was a machine shop class and the other was a more advanced “overall” rebuild class. My main assignment was to COMPLETELY disassemble, blueprint/test everything, and then reassemble a 2001 GSXR-1000 from the crank up. Compared to a GS it’s like a rocket! I learned a TON during this process and I’ve already applied it to my GS project. I’ll share some of what I’ve learned below.

My summer “project” bike (a great, great grandson of my GS).


For example, I learned how to recondition valve seats and valves in the course. I used these skills to clean up my GS valves and re-lap them a bit. Here are some pics of the valves from the GS.

Before – pitted.


Note the white color on this one. This valve was from a very lean running bike.


After a four-stage process on the wheel they looked more like this….


Seats cleaned up:


Next up was a little de-glazing of the cylinders. After sitting for 20+ years, there were some clear ring marks in them. The cross-hatching was also very faint. Within a few minutes using one of these rigs…..


…..I was able to get the cylinders looking more like this.


More in next post…

[D-Mac]

September 15 continued (part 2)….

This August also brought lots of new changes. I moved to a much bigger place with two large garages. One for my wife and one for ME! “My” garage has two parts – an L-shaped outer garage that was built a couple of years ago (600 sqft) and an older inner part that is about 520 sqft. I decided to insulate and re-wire the inner garage as my shop. I will heat it in winter. I started by insulating it completely, installing OSB, priming and painting the walls, re-wiring everything (including all new lighting), and fixing the door. It’s nearly done, although I haven’t really organized or unpacked anything yet.

Some pics of my new “shop”:

Insulation is done and OSB walls are up.



Yesterday. Painted, finished wiring new lights, and now ready to start moving in and working on the GS again!



The new house has also brought a lot of new maintenance things to keep me distracted (massive lawn, pool, new garden to dig, etc. etc.), so I’m just now re-focusing on the bike.

My new gauges came in. Sweet!


I think I like them in this spot. Looks compact and pretty retro. I need to re-locate the ignition and replace it with something that actually works (mine is pretty much toast anyway).


Here are some other pics of the bike as it sits right now:




I’ve also started prepping the top-end. I did the valve seals tonight, and put back in three of the valves so far. My cheap valve spring compressor seems to work fine. For assembly lube I’m using STP, even though it can cause slippage problems for a wet clutch if you use a lot of it. It sticks well and all of the mechanics I worked with over the summer use it on every engine they touch. I figure that if it works OK on a modern sportbike, it’ll be OK on a GS too. Hell, I don’t even know if my clutch is any good anyway.

The head ready for valves:


More in next post….

[D-Mac]

September 15 continued (part 3)…..

Magical assembly lube:


I need to work on getting the tank and seat cowling painted. I have piston rings too, so I think I can continue working on the engine for a while (I still gotta paint the bottom end and swap parts between the two engines I have). I have a lot of wiring challenges coming up too.

I also picked up this little guy. 1975 Honda CB125S. Runs rough, but looks almost like new and has super low miles. I am teaching a first-year college class that will include having the students take it apart and getting it running better. Fun! The 6-volt electrical system is a bit of a pain though.

[D-Mac]

September 15 continued (part 3)…..

Magical assembly lube:


I need to work on getting the tank and seat cowling painted. I have piston rings too, so I think I can continue working on the engine for a while (I still gotta paint the bottom end and swap parts between the two engines I have). I have a lot of wiring challenges coming up too.

I also picked up this little guy. 1975 Honda CB125S. Runs rough, but looks almost like new and has super low miles. I am teaching a first-year college class that will include having the students take it apart and getting it running better. Fun! The 6-volt electrical system is a bit of a pain though.

[Mr.Black]

whoa

[D-Mac]

September 17, 2012

Yesterday I put the rest of the valves back in. Nothing unusual to report here. A few pics….






Since I now have a good shop space at home, I decided to bring the original engine home from my office. Recall that I’m using the bottom end of this engine, along with the covers I polished, but I will be replacing the cylinders/pistons and the rest of the top-end from the lower-mileage parts engine I’ve been rebuilding from scratch.




My next step is to strip down this engine to paint the bottom end. Then I can FINALLY reassemble everything and get it back in the bike!

[coho]

go, man, go!

[Meemuh]

Looks good - and I've got some serious Old Testament coveting of your garage situation.
Nice digs, man.